JP4470527B2 - Decorative sheet - Google Patents

Description

  The present invention relates to a decorative sheet that is used as a decorative board by being bonded to the surface of a wooden board, an inorganic board, a metal plate or the like with an adhesive.

  Conventionally, a vinyl chloride resin sheet has been the most common as a decorative sheet used for the decorative board. However, in recent years, vinyl chloride resin has become a factor in the generation of hydrogen chloride and dioxins, which are extremely toxic substances, which cause acid rain during incineration. Further, there is a problem of bleeding out of the plasticizer added to the vinyl chloride resin sheet, and it has been regarded as a problem from the viewpoint of environmental protection. Under such circumstances, a decorative sheet using a resin replacing the vinyl chloride resin has been demanded.

  Therefore, a decorative sheet using a resin, such as polyethylene, polypropylene polyethylene terephthalate, ethylene-vinyl alcohol, acrylic or urethane, and a copolymer thereof as a substitute for the vinyl chloride resin has been proposed.

  Among them, we have proposed a number of decorative sheets using polypropylene that have the appropriate flexibility, wear resistance, scratch resistance, heat resistance, chemical resistance, post-processing properties, etc. required for decorative sheets and that are supplied at low cost. Has been. Some of them are single-layered, but since design is also emphasized, most of them consist of a laminate of two or more layers.

  The decorative sheet was originally devised as a substitute for a genuine decorative board such as a veneer, and a transparent resin layer was applied to print a wood grain pattern to give a more realistic design and to express a feeling of painting and thickness. There are also many products that are laminated to each other or have a textured pattern (hereinafter referred to as “emboss”) on the surface to give a feeling of touch.

However, even the embossing type decorative sheet with the highest design feeling is often inferior in terms of painting feeling and wall thickness as compared with a genuine veneered decorative sheet. The present inventors considered that this is because a deep coating feeling and wall thickness appearing by coating many layers on an actual veneer cannot be expressed by a single resin layer and embossing. Although it is possible to improve the design feeling when viewed from a distance by making the embossing large and clear, the design feeling and touch feeling when viewed close to each other are greatly impaired. On the other hand, if the emboss is reduced to give a feeling of painting, the depth will be lost.
1994 Patent Application No. 171025 Patent No. 3194403

  The present invention has been made in order to solve the above-mentioned problems, and the object of the present invention is to use a material other than vinyl chloride resin and have a decorative sheet having a design comparable to that of a veneer-coated decorative board. Is to provide.

The present invention is for solving such problems, and the invention according to claim 1 includes at least a base material layer, a picture layer, an adhesive layer comprising an adhesive, an olefin resin, an acrylic resin, or a polyester resin. Alternatively, in a decorative sheet having a transparent or translucent protective layer made of urethane resin, polyvinyl alcohol resin or a copolymer thereof in this order, and having the protective layer as an outermost layer, the protective layer is on the surface and the inner surface. Dissimilar concavo-convex processing has been applied, and the concave portion due to the concavo-convex pattern on the surface and the concave portion due to the concavo-convex pattern on the inner surface are colored, and the concave portion due to the concavo-convex pattern on the inner surface is filled with colored ink and the adhesive The decorative sheet is characterized in that

  According to the invention described in claim 1, since no vinyl chloride is used, there is no concern about environmental problems. In addition, the sheet surface has embossing on the inside, but the embossing on the inside is colored and buried, so the unevenness is clear. On the other hand, the unevenness on the surface is buried, so the unevenness is conservative and gives a feeling of painting. Even a seemingly similar structure has completely contradictory effects, and thus exhibits a higher designability than the conventional one. Furthermore, it is possible to provide a decorative sheet that does not impair the feeling of touch.

  Embodiments of the present invention will be described below with reference to the drawings. 1 and 2 show a cross-sectional structure of an embodiment of a decorative sheet according to the present invention.

  The basic structure of the decorative sheet of the present invention is as shown in FIG. As the order of lamination, the protective layer may be further laminated after laminating the picture layer on the base material layer, or the pictorial layer may be laminated on the back surface of the protective layer and then bonded to the base material layer. May be laminated in the order of the picture layer, the base material layer, and the protective layer, and is not particularly limited, but when the picture layer has several kinds of configurations, it is finally desired when viewed from the upper surface side of the protective layer It is necessary to consider the order in which the patterns are stacked so that the patterns appear. As the base material layer 1 of the present invention, an olefin resin, an acrylic resin, a polyester resin, a urethane resin, a polyvinyl alcohol resin, or a copolymer thereof can be used, but is particularly limited thereto. Is not to be done.

  As a method of laminating a pattern, a printing method is generally used, and there are a gravure printing method, an offset printing method, a silk screen printing method, and the like. Although not particularly specified, a gravure printing method is generally used. Also, the ink used is a known one, that is, a colorant such as a dye or pigment or an extender pigment is added to the vehicle, and further a plasticizer, stabilizer, wax, grease, desiccant, curing agent, thickener, dispersant. Ink obtained by arbitrarily adding a filler or the like and sufficiently kneading with a solvent, a diluent or the like may be used.

  In addition, the pattern layer 2 is formed on the arbitrary transfer base sheet different from the base sheet 1 for the decorative sheet by the above-described forming method, and the thermal laminating method, dry laminating method, A method of transferring the pattern layer 2 to the substrate layer 1 by peeling the transfer substrate sheet after bonding to the substrate layer 1 by a wet laminating method, an extrusion laminating method or the like can also be used.

  Whatever the pattern layer 2 is applied, depending on the material of the protective layer 5, some of the material has low adhesion, so surface modification treatment such as corona discharge treatment, flame treatment, plasma treatment, etc. It is known to do in advance.

  Further, when the T-die extrusion method is used as a method for producing the base material layer 1, a synthetic resin material for forming the base material layer 1 is directly colored with a concealing colorant such as a dye or a pigment. It is possible to give a concealing effect by forming the base material layer 1 by extruding from a T die in a heated and melted state.

  As a coloring method of the base material layer 1 in the T-die extrusion method in this case, a fine powdery colorant obtained by treating a pigment with a dispersion aid or a surfactant is colored to form the base material layer 1. A dry color method used by directly mixing in a normal synthetic resin material that is not used, or a non-colored normal synthetic resin material for forming the base layer 1 and a high concentration pigment are melt-kneaded. A master batch method in which pre-dispersed master batch pellets are prepared in advance, and the master batch pellets are dry-blended with an ordinary uncolored synthetic resin material for forming the base layer 1 in an extrusion hopper. However, it is not particularly limited.

  The types of pigments may be those usually used, but inorganic pigments such as titanium oxide, ultramarine blue, cadmium pigment, iron oxide and the like are particularly desirable in consideration of heat resistance and weather resistance. Also, organic pigments such as phthalocyanine pigments and quinacridone pigments can be used. The ratio of the pigment to the resin and the color are appropriately determined in view of the degree of concealment and design properties, and are not particularly limited.

  As the method for applying the pattern layer 2 to the base layer 1, the printing method and the transfer method as described above can be used. Alternatively, a resin having a high concentration of pigment and different flow characteristics from the resin of the base layer 1 is used. Master batch pellets that have been melt-kneaded and pre-dispersed, or wood flour, glass powder, etc. are added to the synthetic resin material provided with the concealability for forming the base material layer 1 and heated to melt and extruded. There is also a method of forming a pattern by masterbatch pellets, wood powder, glass powder or the like on the substrate layer 1 itself having a concealing property. Of course, these methods for forming a color concealing property and a pattern on the base material layer 1 itself can be used in combination with the printing method and the transfer method described above.

  In addition, when using the calendar method as a manufacturing method of the base material layer 1, a similar method, that is, a method of forming a color hiding property or a pattern layer on the base material layer 1 itself, or these methods and the printing method described above, The pattern layer 2 can be formed on the base material layer 1 by a method using a transfer method or the like together.

  The reason why the transparent or translucent protective layer 5 is laminated on the uppermost surface of the decorative sheet according to the present invention is to exhibit design properties, pattern layer protection and scratch resistance, abrasion resistance, chemical resistance, and the like. It is. Further, in order to obtain a touch feeling on the surface of the decorative sheet and a further design feeling, in claim 1 of the present invention, as shown in FIGS. Recess coloring 5b is applied to each to give a more three-dimensional design feeling.

  When the T-die extrusion method is used as a manufacturing method of the protective layer 5, a convex pattern is applied to the surfaces of the cooling roll and the nip roll for cooling and solidifying the molten resin, and the extruded resin is placed between the cooling roll and the nip roll. A method is possible in which molding is performed simultaneously with cooling and solidification, and recesses 5 a are formed on both surfaces of the protective layer 5. When the hot-press embossing method is employed, the concave portions 5a can be formed on both surfaces of the protective layer 5 by hot-pressing the protective layer 5 between the embossing rolls. Whichever method is used, the protective layer 5 needs to act like a cushion between the embossing rolls, so that it needs to have a thickness of at least 50 μm, preferably 100 μm or more, depending on the unevenness of the embossing rolls.

  In addition, the protective layer 5 in which the concave portion 5a is simply formed on one side is formed by the T-die extrusion method or the hot-pressure embossing method, and another concave portion is formed on the back surface by the T-die extrusion method or the hot-pressure embossing method again. It is also possible to form the protective layer 5 having the concave portions 5a on both surfaces by laminating the 5a molded protective layer 5.

  As a method for performing concave coloring 5b on the concave 5a applied, a coloring agent such as a dye or pigment or an extender pigment is added to the vehicle, and further, a plasticizer, a stabilizer, a wax, a grease, a desiccant, a curing agent, an increase agent, and the like. An ink obtained by arbitrarily adding a viscosity agent, a dispersant, a filler, and the like and kneaded sufficiently with a solvent, a diluent, etc. is applied to the entire surface of the protective layer 5 and then embedded in the recess 5a while being scraped off by a doctor, a doctor roll or the like. There is a way.

  As a method for applying ink to the entire surface of the protective layer 5, there are a gravure method, an ink jet method, a spray method, a die coater method, and the like, which may be appropriately selected depending on the line configuration. Also, depending on the material of the protective layer 5, there are some which have low adhesion to the ink, so it is known to perform surface modification treatment such as corona discharge treatment, flame treatment, plasma treatment and the like.

  In the decorative sheet according to the first aspect of the present invention, the base material layer 1 on which the pattern layer 2 is laminated and the transparent or translucent protective layer 5 or the pattern layer 2 are laminated on the back surface of the protective layer 5 in the reverse order. As a method of laminating with the base material layer 1, there are a heat laminating method in which heat and pressure are applied and a dry laminating method and a wet laminating method in which the adhesive layer 3 is attached.

  In the case of bonding by the thermal laminating method, the concave portion 5a applied to the upper surface side of the protective layer 5 is preferably performed at the same time as the thermal lamination, and therefore, a laminate roll having a convex surface processing is used. There is no particular limitation on the laminating conditions, but the laminating temperature may be appropriately selected depending on the material of the protective layer 5, and there is no particular problem as long as the laminating pressure is such that air does not bite.

  In the case of bonding by a dry laminating method or a wet laminating method, there is no particular problem even if there is a recess 5a on the upper surface of the protective layer 5, or simultaneous molding may be performed with hot pressure during laminating. As the adhesive layer 3 to be used, a two-component curable urethane adhesive that forms urethane by reaction of polyol and isocyanate, a moisture curable urethane adhesive that crosslinks by reacting isocyanate end groups with moisture in the air, epoxy Adhesives, rubber adhesives such as chloroprene, acrylic adhesives, EVA adhesives, hot melt adhesives such as EAA, EEA, etc. can be used, and urethane may be selected as appropriate according to the material to be bonded Since adhesives can be used most widely, they are generally used.

  Examples of the method for applying the adhesive layer 3 include a gravure printing method, a roll coating method, an offset method, a die coating method, and the like, which may be appropriately selected depending on the coating amount and the viscosity. However, since the recess 5a exists on the adhesive surface side of the protective layer 5, there is a risk of air biting if there is not a sufficient amount of coating. As a countermeasure, increase the coating amount, apply the adhesive layer 3 on both sides of the adhesive surface, or bury the adhesive layer 3 in the concave portion 5a with a doctor, doctor roll, etc. on the adhesive surface on the protective layer 5 side and apply the adhesive layer 3 again. May be. It is also known that surface modification treatment such as corona discharge treatment, flame treatment, plasma treatment and the like is performed before coating because some of the materials of the protective layer 5 have low adhesion.

  As shown in FIG. 2, the gloss adjustment layer 6 is provided on the outermost surface of the protective layer 5 to adjust the final gloss as a decorative sheet, improve the scratch resistance, improve the wear resistance, prevent static electricity, impart flame resistance, improve the weather resistance, etc. It is possible to give performance. These methods can be carried out in the same manner as conventional treatments made with vinyl chloride resin decorative sheets. Two-component curable urethane paint, urethane-modified acrylic paint, aminoalkyd paint, lacquer paint, ultraviolet light It is possible to appropriately add desired additives to coating liquids such as curable coatings and electron beam curable coatings. It is also known that coating is performed after surface modification treatment such as corona discharge treatment, flame treatment, plasma treatment and the like because some materials of the protective layer 5 have low adhesion.

Further, as shown in FIG. 2, a primer layer 4 is provided on the outermost lower surface of the base material layer 1 to improve adhesion when a decorative sheet and a member (plywood, MDF, particle board, inorganic board, metal plate, etc.) are bonded together. It is possible to do. Primers include two-component curable urethane-based, urethane-modified acrylic-based, aminoalkyd-based, and lacquer-based, and can be selected according to the application. In addition, depending on the material of the base material layer 1, there is a material having low adhesion, so that it is also known to perform coating after performing surface modification treatment such as corona discharge treatment, flame treatment, and plasma treatment.
It is also possible to provide the pattern layer 2 on the lower surface of the base material layer 1 to give the same effect as the primer layer 6.

As shown in FIG. 1, the base layer 1 is made of an acrylic resin containing 6% by weight of an inorganic pigment, 0.2% by weight of a phenolic antioxidant, 0.3% by weight of a hindered amine light stabilizer, and an antiblocking agent. Using a 80 μm thick sheet obtained by melting and extruding 0.2 wt% of resin, and using a pattern ink on the surface of the sheet by gravure printing (Toyo Ink Manufacturing Co., Ltd .: Lamister) The pattern layer 2 was formed.
Separately, 0.2% by weight of a phenolic antioxidant, 0.3% by weight of a hindered amine light stabilizer, 0.5% by weight of a benzotriazole UV absorber, and 0.2% of an antiblocking agent A transparent acrylic resin film with a thickness of 100 μm added is heated to 140 ° C. and passed between a cooling roll and a nip roll provided with conduit embossing to give an embossed recess 5a on one side, and then an embossed recess formed Colored ink was applied to the entire surface by gravure printing on 5a, and the embossed recessed portion 5a was colored 5b in the recessed portion 5a while scraping with a doctor roll to obtain a protective layer 5 having a thickness of 100 μm. Next, the surface of the protective layer 5 on which the embossed recesses 5a are not formed and the base material layer 1 on which the pattern layer 2 is formed are heat-sealed and embossed recesses 5a are molded simultaneously with a 140 ° C conduit embossing roll. The colored embossed recess 5a is coated on the entire surface by gravure printing, and then the embossed coloring 5b is applied by embedding the ink in the recess 5a while scraping with a doctor roll. The decorative sheet of the present invention shown in FIG. Obtained.

  As shown in FIG. 2, as a base material layer 1, an inorganic pigment is 6% by weight in polypropylene resin, a phenolic antioxidant is 0.2% by weight, a hindered amine light stabilizer is 0.3% by weight, and an antiblocking agent. Using a sheet in which 0.2% by weight of a resin is molded to a thickness of 80 μm by a calendar method, and using a pattern ink (made by Toyo Ink Manufacturing Co., Ltd .: Lamister) on the surface of the sheet by a gravure printing method. A grain pattern was applied to form a pattern layer 2.

Separately, 0.2% by weight of a phenolic antioxidant, 0.3% by weight of a hindered amine light stabilizer, 0.5% by weight of a benzotriazole UV absorber, and 0.2% of an antiblocking agent % Of polypropylene resin added to each other is melt-extruded from a T-die between a cooling roll and a pressure roll that have been embossed by conduit, embossed on both sides at the same time, and then colored on the embossed recesses formed on both sides The ink was applied to the entire surface by a gravure printing method, and then the embossed recess was colored while being scraped off by a doctor roll to obtain a protective layer 5 having a thickness of 100 μm. Next, a two-component curable urethane adhesive (manufactured by Toyo Morton: TM-593) is gravure coated at a coating amount of 10 g / m 2 on the pattern layer 2 to form the adhesive layer 3, and the protective layer 5 is dry laminated. After that, the surface of the protective layer 5 was subjected to corona discharge treatment, and a urethane-modified acrylic paint was coated with 6 g / m 2 gravure. Finally, the back surface of the base material layer 1 was subjected to corona discharge treatment and 2 g / m 2 gravure-coated with a moisture-curable urethane primer to obtain the decorative sheet of the present invention shown in FIG.
<Comparative Example 1>
As a base material layer, 6% by weight of an inorganic pigment, 0.2% by weight of a phenolic antioxidant, 0.3% by weight of a hindered amine light stabilizer, and 0.2% by weight of an antiblocking agent were added to an acrylic resin. Using a 80 μm thick sheet obtained by melt-extruding the resin, a pattern pattern was formed on the surface of the sheet using a gravure printing method using a pattern ink (Toyo Ink Manufacturing Co., Ltd .: Lamister). .

This substrate layer with a pattern layer and a transparent acrylic resin film having a thickness of 100 μm (0.2% by weight of a phenolic antioxidant, 0.3% by weight of a hindered amine light stabilizer, 0% of a benzotriazole ultraviolet absorber) 0.5% by weight and 0.2% by weight of an anti-blocking agent) was heated to 140 ° C. and passed between a cooling roll with conduit embossing and a normal nip roll while embossing was performed on one side. After fusing, a colored ink was applied to the formed embossed recesses by the gravure printing method, and then the embossed recesses were colored by embedding in the recesses while scraping with a doctor roll to obtain a decorative sheet.
<Comparative example 2>
As a base material layer, 6% by weight of an inorganic pigment, 0.2% by weight of a phenolic antioxidant, 0.3% by weight of a hindered amine light stabilizer, and 0.2% by weight of an antiblocking agent were added to a polypropylene resin. Using a sheet of resin molded to a thickness of 80 μm by the calendering method, apply a wood grain pattern to the surface of the sheet by gravure printing using a pattern ink (manufactured by Toyo Ink Manufacturing Co., Ltd .: Lamister). Formed.

  Separately, 0.2% by weight of a phenolic antioxidant, 0.3% by weight of a hindered amine light stabilizer, 0.5% by weight of a benzotriazole UV absorber, and 0.2% of an antiblocking agent % Of the polypropylene resin added with melt is extruded through a T-die between a cooling roll with conduit embossing and a normal pressure roll, embossed on one side, and then colored ink is applied to the shaped embossed recess After coating on the entire surface by the gravure printing method, embossed concave portions were colored in the concave portions while scraping with a doctor roll to obtain a protective layer having a thickness of 100 μm. Next, a two-component curable urethane adhesive (manufactured by Toyo Morton: TM-593) is gravure coated onto the pattern layer at a coating amount of 10 g / m 2, and a protective layer is laminated on the surface, and then the surface of the protective layer is coated. Corona discharge treatment was performed, and 6 g / m 2 gravure coating of urethane-modified acrylic paint was performed. Finally, the back surface of the base material layer 1 was subjected to corona discharge treatment, and a moisture-curable urethane primer was coated with 2 g / m 2 gravure to obtain a decorative sheet.

  Thus, about each decorative sheet obtained in the said Examples 1 and 2 and Comparative Examples 1-2, designability evaluation was performed in five steps evaluation and the result is shown in following Table 1.

  The decorative sheet of the present invention can be used as a decorative board by being bonded to the surface of a wooden board, an inorganic board, a metal plate or the like with an adhesive.

It is explanatory drawing which shows the state of the side cross section of one Example of the decorative sheet by this invention. It is explanatory drawing which shows the state of the side cross section of the other Example of the decorative sheet by this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Base material layer 2 ... Picture layer 3 ... Adhesive layer 4 ... Primer layer 5 ... Protective layer 5a ... Embossing recessed part 5b ... Recessed colored ink 6 ... Gloss adjustment layer

Claims (1)

At least a base material layer, a pattern layer, an adhesive layer made of an adhesive, an olefin resin, an acrylic resin, a polyester resin, a urethane resin, a polyvinyl alcohol resin, or a copolymer thereof, or a transparent or translucent protective layer In the decorative sheet having the protective layer as an outermost layer in this order, the protective layer is subjected to different unevenness processing on the surface and the inner surface, and depending on the recesses due to the unevenness pattern on the surface and the unevenness pattern on the inner surface. A decorative sheet, wherein the concave portion is colored, and the concave portion due to the concave and convex pattern on the inner surface is filled with the colored ink and the adhesive.

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